After a 250 mile trip to Glacier NP loaded with camping gear for 5 of us and a 800 mile trip to the Tahoe Area with just my wife and 2 year old, I decided it was time to get a roof rack. Couldn't justify $1600 for a Gobi and wanted something more substantial than a Curt w/ extensions.

Looks good man! Probably going to end up going the same route, no way I can drop 1600 on a roof rack either.. Couple questions: what did you use to bend the tubing? What size/thickness tubing did you use?

Always funner and more satisfying to do it yourself, nice work !
Did you do the rivnuts on the front section of the factory rails ? They come close to the sunroof but line up out of the way so you don't hit the drip pan. Make sure to seal them when you're done.

Looks good man! Probably going to end up going the same route, no way I can drop 1600 on a roof rack either.. Couple questions: what did you use to bend the tubing? What size/thickness tubing did you use?

I used 3/4 round tube with 0.065 wall from a local metal supply company. You could use the 1/2 EMT conduit from a big box store, but welding galvanized metal is bad for you. Plus, 1/2 EMT only has a wall thickness of 0.042.